Optimalization Design Rules

Optimization of design rules for power transformers through FEA
International conference on New trends in design and Technical Documentation 2009 Peter Arras
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Ing. Peter Arras De Nayer, Belgium
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Introduction Transformer design 2D Optimalisation of the design process Evaluation of existing design rules FEA analaysis and conclusions 750MVA transformer Conclusions.
Power transformers: tailor made.

Pauwels Trafo:
60 years of tradition in transformers 2000 employees Represented in 135 countries
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Design of housing: 2D CAD
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Example of 375 MVA transformer. Overall dimensions of housing: approximatif 5x2.5x3 mm
Design through 2D CAD:

Design based on experience Design rules lead to a library of components which is not changed. Design rules are static: no changes because the impact on the CAD-design would be to great. Errors common to 2D design:
Missing/different dimensions in different views Missing components: too small details on the big overall drawing were left out for the sake of the drawing, but forgotten for the extraction of working drawings.
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Optimalisation of the design process. Evaluate existing design rules Calculate through FEA strengths of housings: calculations demanded by the customers. Restructure design to 3D CAD. Minimize dimensional errors
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Scheme of approach:
Evaluation of existing design rules:
Calculation of 1 existing design Calculation of 5 new designs with existing design rules
Conclusions Calculation of new 750MVA transformer

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Evaluation of existing design rules

FEA calculation scheme:
Stripping of the 2D design drawing for 3D modelling of the housing. 3D- Modelling of the housing Construction of the FEA-model over the 3D CADmodel Constraining/loading Calculation
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Conclusions.
Stripping of the 2D design drawing
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2D CAD model contains all components for calculation of prices Contains no dimensioning scheme No full projection relation between views
Stripped model.
Simplification of:
Welds (left out) Profiles (no fillets) Components: only housing
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3D model: detail of inside
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Corner reinforcements
FEA calculations
Calculations done with Pro Engineer MechWildfire 3.0.
Test as a design tool Quick
Evaluate design rules:

Plate thickness Distance between strengthenings Shape of strengthenings
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Evaluate possible 3D design

Recuperation of 3D CAD effort?
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FEA model
Analysis type: 3D shell model Loadcases:
Vacuum load: zero pressure on inside, bottom of transformer constrained to ground Lifting of transformer: weight of active part, weight and hydrostatic pressure of oil filling, own weight, constrained on 3 out 4 lifting hooks. Jacking of transformer: weight of active part, weight and hydrostatic pressure of oil filling, own weight, constrained on 3 out 4 standing feets/weel bases
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FEA model
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Conclusions
Design rules:
Major design rules can be kept Allowable material strength has to be reduced from 240 MPa to 215 MPa
3D CAD solution:
Complete 3D (detailed) design demands:
Training of personel Rework of CAD-libraries
Only minor gain for FEA model:

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Needs a lot of stripping, feature removal
Solves:
dimensional errors. Missing components.
750 MVA transformer.
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750 MVA transformer

Biggest transformer ever build at Pauwels Trafo Some facts:
total weight 306.5 tons active part: 131 tons housing 10x4x4m high voltage isolators 1800 kg/each Oil filling: 90000 l
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Needs calculation of housing, cover and beams for active part
750 MVA transformer: calculation of housing Applied rules:

Distances between strengthenings according to old rules Material allowable strength: 215 MPa Inner reinforcement triangles substituted with long plate
Calculation:
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Load: vacuum, lifting and jacking. Special care taken on excentric loading due to heavy weight of high voltage isolators and fitting.
750 MVA transformer: 3D stripped model
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750 MVA transformer: FEA model
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6000 shell elements, 7 beams and 3 mass-elements
Results after adding extra reinforcements
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Vacuumload.
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Stress while jacking the housing.
Conclusions.
After 3D modelling the housing:
Dimensional mistakes in 2D CAD drawing corrected
After calculation:
Extra strengthening needed around high voltage fittings Excessive bending in right end wall.
On design rules:
New rules result in fair design Decreased allowable stress together with simple increasing of wall thickness leads to easy changes in the design. In earlier cases design were worked over with more profiles, repositioning etc, which were time- and money consuming.
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Optimalization Design Rules

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Optimalization Design Rules

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Optimization of design rules for power transformers through FEA

Ing. Peter Arras De Nayer, Belgium

Power transformers: tailor made.

Design of housing: 2D CAD

Example of 375 MVA transformer. Overall dimensions of housing: approximatif 5x2.5x3 mm

Design through 2D CAD:

Conclusions Calculation of new 750MVA transformer

Evaluation of existing design rules

Stripping of the 2D design drawing

3D model: detail of inside

Evaluate design rules:

Evaluate possible 3D design

Only minor gain for FEA model:

Needs a lot of stripping, feature removal

750 MVA transformer.

750 MVA transformer

Needs calculation of housing, cover and beams for active part

750 MVA transformer: calculation of housing Applied rules:

750 MVA transformer: 3D stripped model

750 MVA transformer: FEA model

6000 shell elements, 7 beams and 3 mass-elements

Results after adding extra reinforcements

Stress while jacking the housing.

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